Method of manufacturing of a firearm component

ABSTRACT

Disclosed is a method of manufacturing one or more components of a firearm. The method includes forming a magnesium blend alloy ZK60A body. Further, the method includes processing the magnesium blend alloy ZK60A body to form the one or more components of the firearm.

This application claims priority from provisional patent applications No. 62/246,463, filed on Oct. 26, 2015, titled “Alloy Blend for M1911 Handgun Parts and Pistol Receivers” and No. 62/363,963, filed on Jul. 19, 2016, titled “Versatile Upper Receiver for AR-15/Modern Sporting Rifles/M-16/M-4”.

FIELD OF THE DISCLOSURE

Generally, the disclosure relates to manufacturing firearms. More specifically, the disclosure relates to manufacturing components of a firearm using a magnesium alloy.

BACKGROUND

Firearms are portable devices (guns) that launch projectiles (bullets) by the action of an explosive force. Firearms have been in use for many centuries. Various types of firearms include handguns (pistols) and long guns (rifles, carbines and shotguns) used by military, law enforcement personnel, and individuals for hunting and target shooting throughout the world.

A handgun is a firearm designed to be handled in either one or both hands. A long gun is generally any firearm that is larger than a handgun and is designed to be held and fired with both hands, either from the hip or from the shoulder. For example, the Model 1911 handgun is one of the most popular handguns of all times originating in the late 1890s. 1911 handguns are commonly used for self-defense and competition and numerous variations have been developed over the years, for example, a variant known as the Model 1911-A1 uses a single column magazine in which the rounds are stacked linearly on top of one another. Many, if not all, firearms available today have original equipment manufacturer (OEM) and aftermarket components designed to allow modifications to the firearm variant based on the user's preferences. These modifications generally do not replace the main components of the firearm, frame, slide, and receiver (upper and lower if carbine).

Typically, a firearm includes many components, such as a slide, barrel, muzzle, hammer, grip, safety lock, magazine assembly and a receiver. Many of the components of firearms are constructed from materials with high strength and impact-resistant properties. For example, some firearms are fabricated using components made of a combination of the following: stainless steel, iron-containing materials, non-iron containing materials, and polymeric materials. Further, firearm components are generally manufactured using various techniques such as metal stamping, machining, milling, metal forming, casting, forging, and other techniques. Since many components of firearms are manufactured using heavy materials; the weight of firearms can be substantial.

Therefore, there is a need to manufacture lightweight firearms, without reducing the durability and functionality of the firearms and their components. In general, there is a need for improved firearms and methods of manufacturing firearms.

SUMMARY

Disclosed is a method of manufacturing one or more components of a firearm. The method includes forming a magnesium blend alloy ZK60A body. Further, the method includes processing the magnesium blend alloy ZK60A body to form the one or more components of the firearm.

Further disclosed is a firearm comprising a receiver made of the magnesium blend alloy ZK60A body, wherein the receiver may be operably coupled with a barrel. The firearm further includes a slide securable to the receiver.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates a flow chart of a method of manufacturing a component of a firearm using a magnesium blend alloy ZK60A, in accordance with an embodiment.

FIG. 2 illustrates a side view of a handgun component produced using the magnesium blend alloy ZK60A, in accordance with an embodiment.

FIG. 3 illustrates a receiver billet of the Model 1911 handgun before Computer Numerical Control (CNC) operation, in accordance with an embodiment.

FIG. 4 illustrates a receiver and slide billet of the Model 1911 handgun before CNC operation, in accordance with an embodiment.

FIG. 5 illustrates the Model 1911 handgun billet after water jetting but before CNC operation, in accordance with an embodiment.

FIG. 6 illustrates the Model 1911 handgun receiver after CNC operation, in accordance with an embodiment.

FIG. 7 illustrates a right side of the Model 1911 handgun, in accordance with an embodiment.

FIG. 8 illustrates a left side of the Model 1911 handgun, in accordance with an embodiment.

DETAILED DESCRIPTION

Exemplary embodiments are described with reference to the accompanying drawings. Wherever convenient, the same reference numbers are used throughout the drawings to refer to the same or like parts. While examples and features of disclosed principles are described herein, modifications, adaptations, and other implementations are possible without departing from the spirit and scope of the disclosed embodiments. It is intended that the following detailed description be considered as exemplary.

FIG. 1 illustrates a flow chart of a method 100 of manufacturing a component of a firearm using a magnesium blend alloy ZK60A, in accordance with an embodiment. The magnesium blend alloy ZK60A may be aged and hardened to T5, and may be hereinafter referred to as magnesium blend alloy ZK60A-T5. Further, the firearm may be a handgun; for example, a model 1911 handgun, an Arcadia Machine & Tool (AMT) Hardballer, a Ballester-Molina, an Obregón pistol, a Vis pistol or a Kongsberg Colt. Yet further, the firearm may be a long gun; for example, a rifle, a shotgun or a carbine. Moreover, the firearm may be a manual, semi-automatic or an automatic firearm.

FIG. 2 illustrates a side view of a component 200 of a model 1911 handgun that may be manufactured using the magnesium blend alloy ZK60A employing the method 100. The model 1911 handgun may include one or more components such as a slide, a barrel, a muzzle, a hammer, a grip, safety lock, a magazine assembly, and a receiver. Specifically, FIG. 2 illustrates a receiver 200 of the model 1911 handgun that may be produced using the magnesium blend alloy ZK60A employing the method 100. The receiver 200 provides housing for one or more of a hammer, a bolt and a firing mechanism. The receiver 200 may be one of a full frame of the receiver, a half-frame of the receiver or an 80 percent receiver.

At 102, the method 100 includes forming a magnesium blend alloy ZK60A body. For example, the forming may include one or more of casting, forging, molding, performing additive manufacturing, extruding, machining, abrasive waterjet cutting, or stamping one or more pieces of magnesium blend alloy ZK60A. For example, the one or more pieces of magnesium blend alloy ZK60A may include a billet of magnesium blend alloy ZK60A, a bar of magnesium blend alloy ZK60A or chips of magnesium blend alloy ZK60A.

In an exemplary embodiment, the forming the magnesium blend alloy ZK60A body includes using a molding machine. First, the chips of magnesium blend alloy ZK60A and an inert gas supply may be fed to the molding machine. Then, the heating elements of the molding machine may melt the chips of magnesium blend alloy ZK60A to create semi-molten magnesium blend alloy ZK60A. The inert gas may prevent the magnesium from igniting. Next, the semi-molten magnesium blend alloy ZK60A may be forced into a mold of a component of a firearm under high pressure. Finally, the mold may be opened after it cools to retrieve the component of the firearm.

In another exemplary embodiment, the forming the magnesium blend alloy ZK60A body includes performing a Computer Numerical Control (CNC) operation using a CNC machine. The CNC machine includes a workbed, a carriage, a tool and a controller. A receiver billet 300 (shown in FIG. 3) of magnesium blend alloy ZK60A may be placed over the workbed. The receiver billet 300 includes a pattern of the receiver 200 of the Model 1911 handgun. The carriage may then move the tool over the workbed, wherein the controller controls the operation of the tool. The tool essentially follows the pattern on the receiver billet 300.

In yet another exemplary embodiment, forming the magnesium blend alloy ZK60A body includes using the receiver billet 300 and a slide billet 400 (shown in FIG. 4). First, water jetting (or abrasive waterjet cutting) may be used to cut out a rough receiver 500 from the receiver billet 300, as shown in FIG. 5. The rough receiver 500 may be the main frame of the receiver without the holes (for pins and bolts), depressions (for slides), and various other design features. The rough receiver 500 may be placed over the workbed of a CNC machine to perform CNC operation. FIG. 6 illustrates a Model 1911 handgun receiver 600 obtained after CNC operation in accordance with an embodiment.

At 104, the method 100 includes processing the magnesium blend alloy ZK60A body to form the component 200 of the firearm. The processing includes one or more of plating, polishing, deburring and machining. For example, the plating may include forming a layer of nickel over the magnesium blend alloy ZK60A body. The plating may also include applying a ceramic coating over the magnesium blend alloy ZK60A body or the nickel layer.

The method 100 may be used to create longevity for residual wear by increasing functionality and durability of components of a firearm, while decreasing weight. Apart from the receiver 200, other components of the firearm may be manufactured using the magnesium blend alloy ZK60A-T5, by machining of the components from a solid billet.

Further, the processing may include attaching additional elements like a grip. After processing, the final product may be obtained. FIG. 7 illustrates a right side of the Model 1911 handgun 700 obtained after processing. FIG. 8 illustrates a left side of the Model 1911 handgun 700.

According to another embodiment, a firearm is disclosed. The firearm includes a receiver comprising magnesium blend alloy ZK60A body, wherein the receiver is operably coupled with a barrel. The firearm further includes a slide securable to the receiver. The firearm may be a handgun or a long gun. The magnesium blend alloy ZK60A is aged and hardened to T5, wherein a method of manufacturing at least one component of a firearm includes forming a magnesium blend alloy ZK60A body, and processing the magnesium blend alloy ZK60A body to form the at least one component of the firearm; wherein the forming the magnesium blend alloy ZK60A body comprises at least one of casting, forging, molding, performing additive manufacturing, extruding, machining, abrasive waterjet cutting, or stamping at least one piece of magnesium blend alloy ZK60A; and the processing the magnesium blend alloy ZK60A body includes at least one of plating, polishing, or deburring.

According to an exemplary embodiment, the forming includes one or more of face milling, contour milling, spot milling, pocketing, drilling, center-drilling, or rigid tapping. The processing includes performing a rough three dimensional (3D) surfacing and a finishing 3D surfacing.

Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention. 

We claim:
 1. A method of manufacturing at least one component of a firearm, the method comprising: forming a magnesium blend alloy ZK60A body; and processing the magnesium blend alloy ZK60A body to form the at least one component of the firearm.
 2. The method of claim 1, wherein the firearm is a handgun.
 3. The method of claim 2, wherein the handgun is a model 1911 handgun.
 4. The method of claim 2, wherein the handgun is at least one of model 1911 handgun, AMT Hardballer, Ballester-Molina, Obregón pistol, Vis pistol, or Kongsberg Colt.
 5. The method of claim 1, wherein the firearm is a long gun, wherein the long gun is at least one of a rifle, a shotgun, or a carbine.
 6. The method of claim 1, wherein the firearm is at least one of a manual, semi-automatic, or an automatic firearm.
 7. The method of claim 1, wherein the at least one component includes a slide, a barrel, a muzzle, a hammer, a grip, a safety lock, a magazine assembly and a receiver.
 8. The method of claim 1, wherein the at least one component is a receiver, wherein the receiver provides housing for at least one of a hammer, a bolt, or a firing mechanism.
 9. The method of claim 8, wherein the forming includes making at least one of a full frame of the receiver, two half-frames of the receiver, or an 80 percent receiver.
 10. The method of claim 1, wherein the magnesium blend alloy ZK60A is aged and hardened to T5.
 11. The method of claim 1, wherein the forming the magnesium blend alloy ZK60A body comprises at least one of casting, forging, molding, performing additive manufacturing, extruding, machining, abrasive waterjet cutting, or stamping at least one piece of magnesium blend alloy ZK60A.
 12. The method of claim 11, wherein the at least one piece of magnesium blend alloy ZK60A includes at least one of a billet of magnesium blend alloy ZK60A, a bar of magnesium blend alloy ZK60A, or chips of magnesium blend alloy ZK60A.
 13. The method of claim 12, wherein the molding includes using a molding machine, wherein the chips of magnesium blend alloy ZK60A and an inert gas supply are fed to the molding machine, wherein heating elements of the molding machine melt the chips of magnesium blend alloy ZK60A to create semi-molten magnesium blend alloy ZK60A, which is then forced into a mold of the at least one component of a firearm under high pressure, wherein the mold is opened after it cools to retrieve the at least one component of a firearm.
 14. The method of claim 13, wherein the machining includes using a Computer Numerical Control (CNC) machine, wherein the CNC machine includes a workbed, a carriage, a tool and a controller, wherein the at least one piece of magnesium blend alloy ZK60A is placed over the workbed, and the carriage moves the tool over the workbed, wherein the controller controls the operation of the tool.
 15. The method of claim 1, wherein the processing the magnesium blend alloy ZK60A body includes at least one of plating, polishing, deburring, or machining.
 16. The method of claim 1, wherein the plating includes at least one of forming a layer of nickel over the magnesium blend alloy ZK60A body or applying a ceramic coating over the magnesium blend alloy ZK60A body.
 17. The method of claim 1, wherein the forming includes at least one of face milling, contour milling, spot milling, pocketing, drilling, center-drilling, or rigid tapping; and the processing includes performing three dimensional surfacing.
 18. A firearm comprising: a receiver comprising magnesium blend alloy ZK60A body, wherein the receiver is operably coupled with a barrel; and a slide securable to the receiver.
 19. The firearm of claim 18 is at least one of a handgun or a long gun.
 20. The firearm of claim 18, wherein the magnesium blend alloy ZK60A is aged and hardened to T5, wherein a method of manufacturing at least one component of a firearm includes forming a magnesium blend alloy ZK60A body, and processing the magnesium blend alloy ZK60A body to form the at least one component of the firearm; wherein the forming the magnesium blend alloy ZK60A body comprises at least one of casting, forging, molding, performing additive manufacturing, extruding, machining, abrasive waterjet cutting, or stamping at least one piece of magnesium blend alloy ZK60A; and the processing the magnesium blend alloy ZK60A body includes at least one of plating, polishing, or deburring. 